U.S. patent application number 13/613454 was filed with the patent office on 2013-04-11 for thermal storage material container and heat exchanger.
This patent application is currently assigned to KEIHIN THERMAL TECHNOLOGY CORPORATION. The applicant listed for this patent is Naohisa Higashiyama, Osamu Kamoshida, Tatsuhiro Mizo. Invention is credited to Naohisa Higashiyama, Osamu Kamoshida, Tatsuhiro Mizo.
Application Number | 20130086938 13/613454 |
Document ID | / |
Family ID | 47751547 |
Filed Date | 2013-04-11 |
United States Patent
Application |
20130086938 |
Kind Code |
A1 |
Higashiyama; Naohisa ; et
al. |
April 11, 2013 |
THERMAL STORAGE MATERIAL CONTAINER AND HEAT EXCHANGER
Abstract
A cool storage material container is formed by brazing together
peripheral edge portions of two aluminum plates. A cool storage
material for storing cool is charged into a cool storage material
accommodation space. The cool storage material container has a seal
portion provided by closing a thermal storage material charging
inlet which is formed at the peripheral edge portions of the two
aluminum plates and is used to charge the cool storage material
into the cool storage material accommodation space. The seal
portion includes two outward protrusions which are formed by
pressing and collapsing the thermal storage material charging inlet
such that they project outward from the two aluminum plates and are
brought into close contact with each other. The outward protrusions
are bonded together by an anaerobic adhesive and are bent in the
thickness direction of the aluminum plates such that their bent
portions have a V-shaped cross section.
Inventors: |
Higashiyama; Naohisa;
(Oyama-shi, JP) ; Kamoshida; Osamu; (Oyama-shi,
JP) ; Mizo; Tatsuhiro; (Oyama-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Higashiyama; Naohisa
Kamoshida; Osamu
Mizo; Tatsuhiro |
Oyama-shi
Oyama-shi
Oyama-shi |
|
JP
JP
JP |
|
|
Assignee: |
KEIHIN THERMAL TECHNOLOGY
CORPORATION
Oyama-shi
JP
|
Family ID: |
47751547 |
Appl. No.: |
13/613454 |
Filed: |
September 13, 2012 |
Current U.S.
Class: |
62/524 ;
220/612 |
Current CPC
Class: |
F28D 20/02 20130101;
F28D 2020/0008 20130101; F28D 2021/0085 20130101; F28D 2020/0013
20130101; F28F 2220/00 20130101; Y02E 60/145 20130101; F28D 1/05391
20130101; F28D 1/00 20130101; F28D 20/00 20130101; Y02E 60/142
20130101; B65D 7/42 20130101; F25B 39/02 20130101; F25B 2400/24
20130101; Y02E 60/14 20130101 |
Class at
Publication: |
62/524 ;
220/612 |
International
Class: |
F25B 39/02 20060101
F25B039/02 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 15, 2011 |
JP |
2011-201332 |
Claims
1. A thermal storage material container which is formed by joining
together peripheral edge portions of two metal plates, the thermal
storage material container having a thermal storage material
accommodation space provided between the two metal plates and
filled with a thermal storage material, and a seal portion provided
by closing a thermal storage material charging inlet which is an
outward projecting tubular portion formed at the peripheral edge
portions of the two metal plates and is used to charge the thermal
storage material into the thermal storage material accommodation
space, wherein the seal portion includes two outward protrusions
which are respectively provided on the two metal plates such that
they project outward from the two metal plates and which are
brought into close contact with each other; and the two outward
protrusions are formed by pressing and collapsing the thermal
storage material charging inlet and are bonded together by an
anaerobic adhesive.
2. A thermal storage material container according to claim 1,
wherein the two outward protrusions bonded by the anaerobic
adhesive are bent in a thickness direction of the metal plates such
that their bent portions have a V-shaped cross section.
3. A thermal storage material container according to claim 2,
wherein the outward protrusions of the two metal plates bonded by
the anaerobic adhesive are bent at a plurality of locations in a
projection direction in which the outward protrusions project from
the peripheral edge portions of the metal plates such that the
bending directions of adjacent bent portions differ from each
other.
4. A thermal storage material container according to claim 1,
wherein the anaerobic adhesive is of a UV curable type and is
hardened in a state in which a portion of the anaerobic adhesive
has flowed outside from an joint interface between the two outward
protrusions.
5. A heat exchanger which is used as an evaporator with a cool
storage function, the heat exchanger comprising a plurality of heat
exchange tubes which extend in a vertical direction and through
which a medium for carrying cool flows, and a plurality of cool
storage material containers filled with a cool storage material for
storing cool, wherein the medium flowing through the heat exchange
tubes is caused to evaporate, the cool storage material container
is the thermal storage material container according to claim 1, and
the heat exchanger is configured such that the cool storage
material within the cool storage material container is cooled by
the cool carried by the medium flowing through the heat exchange
tubes.
6. A heat exchanger according to claim 5, wherein the plurality of
heat exchange tubes are flat tubes whose width direction coincides
with an air-passing direction; the plurality of heat exchange tubes
are disposed in parallel such that they are spaced from one
another; air-passing clearances are formed such that each
air-passing clearance is located between adjacent heat exchange
tubes; the cool storage material containers are flat containers
which extend in the vertical direction and whose width direction
coincides with the air-passing direction; and the cool storage
material containers are disposed in some of all the air-passing
clearances.
7. A heat exchanger according to claim 6, wherein the seal portion
is formed at a leeward portion of each cool storage material
container located on the leeward side of the heat exchange
tubes.
8. A heat exchanger comprising a plurality of heat exchange tubes
through which a medium for carrying heat flows, and a plurality of
heat storage material containers which extend in a vertical
direction and which is filled with a heat storage material for
storing heat, wherein the heat storage material container is the
thermal storage material container according to claim 1, and the
heat exchanger is configured such that heat carried by the medium
flowing through the heat exchange tubes is transferred to the heat
storage material within the heat storage material container.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a thermal storage material
container and a heat exchanger.
[0002] In the present specification and appended claims, the upper
and lower sides of FIG. 1 will be referred to as "upper" and
"lower," respectively.
[0003] For example, in order to protect the environment and improve
fuel consumption of automobiles, there has been proposed an
automobile designed to automatically stop the engine when the
automobile stops, for example, so as to wait for a traffic light to
change.
[0004] However, an ordinary car air conditioner has a problem in
that, when an engine of an automobile in which the air conditioner
is mounted is stopped, a compressor driven by the engine stops, and
supply of refrigerant (medium for carrying cool) to an evaporator
stops, whereby the cooling capacity of the air conditioner sharply
drops.
[0005] One conceivable measure for solving such a problem is
imparting a cool storage function to the evaporator, to thereby
enable cooling of a vehicle compartment by releasing the cool
stored in the evaporator, when the compressor stops as a result of
stoppage of the engine.
[0006] Such an evaporator with a cool storage function has been
proposed (see Japanese Patent Application Laid-Open (kokai) No.
2011-12947). In the proposed evaporator, a plurality of flat
refrigerant flow tubes (heat exchange tubes) which extend in the
vertical direction and whose width direction coincides with an
air-passing direction are disposed in parallel such that they are
spaced from one another. The evaporator has air-passing clearances
each formed between refrigerant flow tubes located adjacent to each
other. Cool storage material containers filled with a cool storage
material are disposed in some air-passing clearances, and outer
fins are disposed in the remaining air-passing clearances. Each
cool storage material container is formed by joining together
peripheral edge portions of two metal plates, and a cool storage
material is charged into a cool storage material accommodation
space provided between the two metal plates.
[0007] Although not clearly shown in the above-mentioned
publication, a cool storage material charging inlet is formed in
each cool storage material container so as to charge the cool
storage material into the cool storage material container. After
the cool storage material is charged into the cool storage material
accommodation space through the cool storage material charging
inlet, the cool storage material charging inlet must be closed.
[0008] Incidentally, in the case of the evaporator with a cool
storage function disclosed in the above-mentioned publication, a
conceivable simple way of forming the cool storage material
charging inlet on each cool storage material container is providing
an outward projecting semi-cylindrical portion at the peripheral
edge of each metal plate, providing outward flanges along opposite
side edges of the semi-cylindrical portion of each metal plate, and
joining together the corresponding outward flanges of the
semi-cylindrical portions of the two metal plates. Also, a
conceivable simple way of closing such a cool storage material
charging inlet is press-fitting a cylindrical columnar plug into
the cool storage material charging inlet after charging of the cool
storage material.
[0009] In general, the two metal plates which constitute the
above-described thermal storage material container are manufactured
by performing press work on a blank metal plate through use of two
dies having shapes corresponding to the final shape of the metal
plates. In this case, round connection portions are unavoidably
formed between the inner circumferential surface of each
semi-cylindrical portion and the outward flanges formed along the
opposite side edges of the semi-cylindrical portion. Accordingly,
when the two metal plates are joined together, recesses are formed
on the inner circumferential surface of the cylindrical thermal
storage material charging inlet formed by the semi-cylindrical
portions of the metal plates. As a result, merely press-fitting a
cylindrical columnar plug into the thermal storage material
charging inlet may cause leakage of the thermal storage
material.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to solve the
above-mentioned problem and to provide a thermal storage material
container which can reliably prevent leakage of a thermal storage
material charged into the thermal storage material container and
provide a heat exchanger using the thermal storage material
container.
[0011] To fulfill the above object, the present invention comprises
the following modes.
[0012] 1) A thermal storage material container which is formed by
joining together peripheral edge portions of two metal plates, the
thermal storage material container having a thermal storage
material accommodation space provided between the two metal plates
and filled with a thermal storage material, and a seal portion
provided by closing a thermal storage material charging inlet which
is an outward projecting tubular portion formed at the peripheral
edge portions of the two metal plates and is used to charge the
thermal storage material into the thermal storage material
accommodation space, wherein
[0013] the seal portion includes two outward protrusions which are
respectively provided on the two metal plates such that they
project outward from the two metal plates and which are brought
into close contact with each other; and the two outward protrusions
are formed by pressing and collapsing the thermal storage material
charging inlet and are bonded together by an anaerobic
adhesive.
[0014] 2) A thermal storage material container according to par.
1), wherein the two outward protrusions bonded by the anaerobic
adhesive are bent in a thickness direction of the metal plates such
that their bent portions have a V-shaped cross section.
[0015] 3) A thermal storage material container according to par.
2), wherein the outward protrusions of the two metal plates bonded
by the anaerobic adhesive are bent at a plurality of locations in a
projection direction in which the outward protrusions project from
the peripheral edge portions of the metal plates such that the
bending directions of adjacent bent portions differ from each
other.
[0016] 4) A thermal storage material container according to par.
1), wherein the anaerobic adhesive is of a UV curable type and is
hardened in a state in which a portion of the anaerobic adhesive
has flowed outside from an joint interface between the two outward
protrusions.
[0017] 5) A heat exchanger which is used as an evaporator with a
cool storage function, the heat exchanger comprising a plurality of
heat exchange tubes which extend in a vertical direction and
through which a medium for carrying cool flows, and a plurality of
cool storage material containers filled with a cool storage
material for storing cool, wherein the medium flowing through the
heat exchange tubes is caused to evaporate, the cool storage
material container is the thermal storage material container
according to par. 1), and the heat exchanger is configured such
that the cool storage material within the cool storage material
container is cooled by the cool carried by the medium flowing
through the heat exchange tubes.
[0018] 6) A heat exchanger according to par. 5), wherein the
plurality of heat exchange tubes are flat tubes whose width
direction coincides with an air-passing direction; the plurality of
heat exchange tubes are disposed in parallel such that they are
spaced from one another; air-passing clearances are formed such
that each air-passing clearance is located between adjacent heat
exchange tubes; the cool storage material containers are flat
containers which extend in the vertical direction and whose width
direction coincides with the air-passing direction; and the cool
storage material containers are disposed in some of all the
air-passing clearances.
[0019] 7) A heat exchanger according to par. 6), wherein the seal
portion is formed at a leeward portion of each cool storage
material container located on the leeward side of the heat exchange
tubes.
[0020] 8) A heat exchanger comprising a plurality of heat exchange
tubes through which a medium for carrying heat flows, and a
plurality of heat storage material containers which extend in a
vertical direction and which is filled with a heat storage material
for storing heat, wherein the heat storage material container is
the thermal storage material container according to par. 1), and
the heat exchanger is configured such that heat carried by the
medium flowing through the heat exchange tubes is transferred to
the heat storage material within the heat storage material
container.
[0021] According to the thermal storage material container of any
one of pars. 1) to 4), the seal portion includes two outward
protrusions which are respectively provided on the two metal plates
such that they project outward from the two metal plates and which
are brought into close contact with each other; and the two outward
protrusions are formed by pressing and collapsing the thermal
storage material charging inlet and are bonded together by an
anaerobic adhesive. Therefore, as compared with the case where a
cylindrical columnar plug is merely press-fit into a cylindrical
thermal storage material charging inlet, leakage of the thermal
storage material charged into the thermal storage material
container can be prevented reliably.
[0022] According to the thermal storage material container of par.
2) or 3), the two outward protrusions bonded by the anaerobic
adhesive are bent in the thickness direction of the metal plates
such that their bent portions have a V-shaped cross section.
Therefore, a spring-back force generated as a result of bending the
two outward protrusions acts in a direction perpendicular to the
ridge line of the V-shaped portion which is the apex of the bent
portion. Accordingly, the outward protrusion located on the inner
side of the bent portion with respect to the bending direction is
pushed against the outward protrusion located on the outer side of
the bent portion with respect to the bending direction. Thus,
formation of a gap between the outward protrusions of the two metal
plates can be prevented reliably, and leakage of the thermal
storage material charged into the thermal storage material
container can be prevented more reliably.
[0023] According to the thermal storage material container of par.
3), since formation of a gap between the outward protrusions of the
two metal plates can be prevented more reliably, leakage of the
thermal storage material charged into the thermal storage material
container can be prevented more reliably.
[0024] According to the thermal storage material container of par.
4), it is possible to visually and externally confirm that the
adhesive hardened in a state in which it has flowed outside from
the joint interface between the two outward protrusions covers the
outer end of the joint interface. Therefore, leakage of the thermal
storage material charged into the thermal storage material
container can be prevented more reliably.
[0025] According to the heat exchanger of any one of pars. 5) to
7), it is possible to reliably prevent leakage of a cool storage
material which is charged into a cool storage material container
and which stores cool.
[0026] According to the heat exchanger of par. 8), it is possible
to reliably prevent leakage of a heat storage material which is
charged into a heat storage material container and which stores
heat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a partially cut-away perspective view showing the
overall structure of an evaporator with a cool storage function in
which a thermal storage material container of the present invention
is used as a cool storage material container;
[0028] FIG. 2 is an enlarged sectional view taken along line A-A of
FIG. 1;
[0029] FIG. 3 is an enlarged perspective view showing a portion of
the cool storage material container used in the evaporator with a
cool storage function of FIG. 1;
[0030] FIG. 4 is a perspective view showing a method of forming a
seal portion of the cool storage material container used in the
evaporator with a cool storage function of FIG. 1; specifically,
showing a state after application of an anaerobic adhesive onto the
inner circumferential surface of a cool storage material charging
inlet;
[0031] FIGS. 5(a) and 5(b) are enlarged vertical sectional views
showing the method of forming the seal portion of the cool storage
material container used in the evaporator with a cool storage
function of FIG. 1; specifically, showing a method of pressing and
collapsing the cool storage material charging inlet shown in FIG. 4
and applied with an anaerobic adhesive;
[0032] FIGS. 6(a) and 6(b) are enlarged vertical sectional views
showing a modification of the method of forming the seal portion of
the cool storage material container used in the evaporator with a
cool storage function of FIG. 1; and
[0033] FIGS. 7(a) to 7(c) are enlarged vertical sectional views
showing another modification of the method of forming the seal
portion of the cool storage material container used in the
evaporator with a cool storage function of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] An embodiment of the present invention will next be
described with reference to the drawings. In this embodiment, a
thermal storage material container of the present invention is
applied to cool storage material containers of an evaporator with a
cool storage function into which a cool storage material for
storing cool is charged.
[0035] Throughout the drawings, like portions and like members are
denoted by the same reference numerals, and their descriptions will
not be repeated.
[0036] In the following description, the downstream side with
respect to an air-passing direction (a direction represented by
arrow X in FIGS. 1 and 2) will be referred to as the "front," and
the opposite side as the "rear." Also, the left-hand and right-hand
sides of FIG. 1 will be referred to as "left" and "right,"
respectively.
[0037] Furthermore, the term "aluminum" as used in the following
description encompasses aluminum alloys in addition to pure
aluminum.
[0038] FIG. 1 shows the overall structure of an evaporator with a
cool storage function in which a thermal storage material container
of the present invention is used as a cool storage material
container, and FIGS. 2 and 3 show the configuration of an essential
portion of the evaporator. Also, FIG. 4 and FIGS. 5(a) and 5(b)
show a method of forming a seal portion of a cool storage material
container used in the evaporator with a cool storage function.
[0039] As shown in FIG. 1, an evaporator 1 with a cool storage
function (heat exchanger) includes a first header tank 2 and a
second header tank 3 formed of aluminum and disposed apart from
each other in the vertical direction such that they extend in the
left-right direction; and a heat exchange core section 4 provided
between the two header tanks 2 and 3.
[0040] The first header tank 2 includes a leeward upper header
section 5 located on the front side (downstream side with respect
to the air-passing direction); and a windward upper header section
6 located on the rear side (upstream side with respect to the
air-passing direction) and united with the leeward upper header
section 5. A refrigerant inlet 7 is provided at the right end of
the leeward upper header section 5, and a refrigerant outlet 8 is
provided at the right end of the windward upper header section 6.
The second header tank 3 includes a leeward lower header section 9
located on the front side, and a windward lower header section 11
located on the rear side and united with the leeward lower header
section 9. The respective interiors of the leeward lower header
section 9 and the windward lower header section 11 of the second
header tank 3 are connected together via a communication member 12
which is joined to the right ends of the two lower header sections
9 and 11 and which has an inner space serving as a passage.
[0041] As shown in FIGS. 1 and 2, in the heat exchange core section
4, a plurality of flat heat exchange tubes 13 which extend in the
vertical direction, whose width direction coincides with the
air-passing direction (the front-rear direction), and which are
formed of aluminum extrudate are disposed in parallel such that
they are spaced from one another in the left-right direction. In
the present embodiment, a plurality of pairs 14 each composed of
two heat exchange tubes 13 spaced from each other in the front-rear
direction are disposed at predetermined intervals in the left-right
direction. Air-passing clearances 15 are formed such that each
air-passing clearance 15 is formed between adjacent two of the
pairs 14 each composed of the front and rear heat exchange tubes
13. An upper end portion of each front heat exchange tube 13 is
connected to the leeward upper header section 5, and a lower end
portion of each front heat exchange tube 13 is connected to the
leeward lower header section 9. Similarly, an upper end portion of
each rear heat exchange tube 13 is connected to the windward upper
header section 6, and a lower end portion of each rear heat
exchange tube 13 is connected to the windward lower header section
11.
[0042] A cool storage material container 16 (thermal storage
material container) which is formed of aluminum and which is filled
with a cool storage material (not shown) for storing cool is
disposed in each of air-passing clearances 15 selected from all the
air-passing clearances 15 of the heat exchange core section 4, the
selected air-passing clearances 15 being not adjacent from one
another, such that the cool storage material container 16 extends
over the front and rear heat exchange tubes 13. Also, a corrugated
outer fin 17 is disposed in each of the remaining air-passing
clearances 15 such that the corrugated outer fin 17 extends over
the front and rear heat exchange tubes 13. The outer fin 17 is
formed from an aluminum brazing sheet having a brazing material
layer on each of opposite surfaces thereof and which has crest
portions extending in the front-rear direction, trough portions
extending in the front-rear direction, and connection portions
connecting the crest portions and the trough portions. The outer
fin 17 is brazed to the front and rear heat exchange tubes 13 of
the left-side and right-side pairs 14 which define the air-passing
clearance 15. That is, the outer fin 17 is disposed in each of the
air-passing clearances 15 located on opposite sides of the
air-passing clearance 15 in which the cool storage material
container 16 is disposed. Also, the outer fin 17, which is formed
from an aluminum brazing sheet having a brazing material layer on
each of opposite surfaces thereof, is disposed on the outer side of
the pair 14 of the heat exchange tubes 13 located at the left end,
and is disposed on the outer side of the pair 14 of the heat
exchange tubes 13 located at the right end. These outer fins 17 are
brazed to the corresponding front and rear heat exchange tubes 13.
Furthermore, a side plate 18 formed of aluminum is disposed on the
outer side of each of the outer fins 17 located at the left and
right ends, respectively, and is brazed to the corresponding outer
fin 17. The spaces between the outer fins 17 and the side plates 18
located at the left and right ends also serve as air-passing
clearances.
[0043] As shown in FIG. 2, each cool storage material container 16
is a flat container whose width direction coincides with the
front-rear direction, and is formed by brazing together peripheral
edge portions of two generally rectangular aluminum plates 19 (meal
plates) extending vertically. A cool storage material is charged
into a cool storage material accommodation space 16a (thermal
storage material accommodation space) provided between the two
aluminum plates 19. Each cool storage material container 16 has a
container main body portion 21 and an outward projecting portion
22. The container main body portion 21 is located rearward of the
front side edges of the front heat exchange tubes 13, and is brazed
to the two (front and rear) heat exchange tubes 13 of each of the
pairs 14 located on opposite sides of the container main body
portion 21. The outward projecting portion 22 extends from the
front side edge (leeward side edge) of the container main body
portion 21, and projects frontward (outward in the air-passing
direction) from the front side edges of the front heat exchange
tubes 13. The interiors of the container main body portion 21 and
the outward projecting portion 22 serve as the cool storage
material accommodation space 16a. The entire container main body
portion 21 of the cool storage material container 16 has a uniform
dimension as measured in the left-right direction. The dimension of
the outward projecting portion 22 of the cool storage material
container 16 as measured in the vertical direction is equal to that
of the container main body portion 21, and the dimension of the
outward projecting portion 22 of the cool storage material
container 16 as measured in the left-right direction is greater
than that of the container main body portion 21 of the cool storage
material container 16. Therefore, in relation to the container main
body portion 21, the outward projecting portion 22 bulges outward
in the left-right direction. The dimension of the outward
projecting portion 22 as measured in the left-right direction is
equal to a height obtained by adding the dimension of the container
main body portion 21 of the cool storage material container 16 in
the left-right direction to the double of a tube height, which is
the dimension of each heat exchange tube 13 as measured in the
left-right direction.
[0044] An inner fin 23 made of aluminum is disposed in each cool
storage material container 16 such that the inner fin 23 extends
from the rear end of the container main body portion 21 to the
front end of the outward projecting portion 22 and extends over
substantially the entire length of the cool storage material
container 16 in the vertical direction. The inner fin 23 is a
corrugated fin which has crest portions extending in the front-rear
direction, trough portions extending in the front-rear direction,
and connection portions connecting the crest portions and the
trough portions. The inner fin 23 has a uniform fin height over the
entirety thereof, and is brazed to the inner surfaces of the left
and right side walls of the container main body portion 21 of the
storage material container 16.
[0045] A paraffin-based latent heat storage material having an
adjusted freezing point of about 5 to 10.degree. C. is used as a
cool storage material charged into each cool storage material
container 16. Specifically, pentadecane, tetradecane, or the like
is used. The cool storage material is charged into each cool
storage material container 16 such that the cool storage material
reaches a point near the upper end of the cool storage material
container 16. Notably, the cool storage material container 16 is
designed to have a sufficient strength within a usual temperature
range of an environment in which the cooling unit is used; for
example, a temperature range of -40.degree. C. to 90.degree. C.,
such that, even when the internal pressure increases due to density
change of the cool storage material in a liquid phase and thermal
expansion of air remaining within the cool storage material
container 16, the cool storage material container 16 does not
break.
[0046] The aluminum plates 19, which constitute each cool storage
material container 16, are each formed, through press work, from an
aluminum brazing sheet having a brazing material layer on each of
opposite sides thereof. Each of the aluminum plates 19 has bulge
portions 19a and 19b, which form the container main body portion 21
and the outward projecting portion 22, respectively, and a rim
portion 19c which remains along the peripheral edge and has a
predetermined width. The two aluminum plates 19 are assembled
together with the inner fin 23 disposed therebetween such that the
openings of the bulge portions 19a and 19b face each other. In this
state, the rim portions 19c of the two aluminum plates 19 are
brazed together, and the inner fin 23 is brazed to the aluminum
plates 19, whereby the cool storage material container 16 is
formed.
[0047] As shown in FIG. 3, an upward projecting seal portion 25 is
provided at the upper end of the outward projecting portion 22 of
each cool storage material container 16. The seal portion 25 is
formed by closing a cool storage material charging inlet 24
(thermal storage material charging inlet; see FIG. 4 and FIG. 5(a))
which is formed at the peripheral edges of the two aluminum plates
19 and which has been used for charging a cool storage material
into the cool storage material accommodation space 16a. The seal
portion 25 include two outward protrusions 26 which are provided on
the aluminum plates 19 such that they project upward therefrom and
which are brought into close contact with each other. The two
outward protrusions 26 are formed by pressing and collapsing the
cool storage material charging inlet 24 from the outside with
respect to the thickness direction of the cool storage material
container 16. The two outward protrusions 26 are bonded together
through use of an anaerobic adhesive 29 (see FIG. 5(b); not shown
in FIG. 3).
[0048] At a plurality of locations (two locations in the present
embodiment) spaced from each other in the vertical direction; i.e.,
in the direction in which the outward protrusions 26 project from
the peripheral edges of the aluminum plates 19, the two outward
protrusions 26 of the seal portion 25 bonded together by the
anaerobic adhesive 29 are bent in the thickness direction of the
aluminum plates 19 such that each bent portion 27 has a V-shaped
cross section. The adjacent bent portions 27 differ in bending
direction. For example, LOCTITE 638 (product of Henkel Corporation)
is used as the anaerobic adhesive 29. In this case, a stable
gastightness and bonding strength can be secured in a temperature
range of -40.degree. C. to 90.degree. C., which is the usual
temperature range of an environment in which the evaporator 1 is
used.
[0049] Each outer fin 17 is a corrugated fin which has crest
portions extending in the front-rear direction, trough portions
extending in the front-rear direction, and connection portions
connecting the crest portions and the trough portions. Each other
fin 17 has a fin main body portion 31 and an outward projecting
portion 32. The fin main body portion 31 is located rearward of the
front side edges of the front heat exchange tubes 13, and is brazed
to the front and rear heat exchange tubes 13 of each of the pairs
14 located on opposite sides of the fin main body portion 31. The
outward projecting portion 32 extends from the front side edge of
the fin main body portion 31, and projects frontward from the front
side edges of the front heat exchange tubes 13. The outward
projecting portions 32 of the outer fins 17 disposed in the
air-passing clearances 15 adjacently located on the opposite sides
of the air-passing clearances 15 in which the cool storage material
container 16 is disposed are brazed to the left and right side
surfaces of the outward projecting portion 22 of the cool storage
material container 16. Also, a spacer 33 formed of aluminum is
disposed between the outward projecting portions 32 of the adjacent
outer fins 17, and is brazed to the outward projecting portions
32.
[0050] The seal portion 25 of each cool storage material container
16 is provided as follows.
[0051] Semi-cylindrical portions 28 for forming the charging inlet
are previously provided at the upper ends of the bulge portions 19b
(which constitute the outward projecting portion 22) of the two
aluminum plates 19, which form the cool storage material container
16. Outward extending flanges 28a are integrally formed along
opposite side edges of each semi-cylindrical portion 28. The
flanges 28a are continuous with the rim portion 19c of the
corresponding aluminum plate 19. The cool storage material
container 16 is manufactured in the above-described manner through
use of such aluminum plates 19, whereby the cool storage material
charging inlet 24 is formed. As shown in FIGS. 4 and 5(a), the cool
storage material charging inlet 24 is provided such that it
projects upward from the upper end of the outward projecting
portion 22. The cool storage material charging inlet 24, which has
a cylindrical tubular shape, is opened at its lower end to the
interior of the outward projecting portion 22, which partially
forms the cool storage material accommodation space 16a of the cool
storage material container 16, and is opened at its upper end to
the outside of the cool storage material container 16. Notably,
manufacture of the cool storage material container 16 may be
performed simultaneously with brazing of the remaining components
of the evaporator 1, or performed separately from the brazing. In
the case where manufacture of the cool storage material container
16 is performed separately from the brazing of the remaining
components of the evaporator 1, after manufacture of the cool
storage material container 16, the cool storage material container
16 is disposed at a predetermined position of the evaporator.
[0052] Subsequently, after the cool storage material is charged
into the cool storage material container 16 through the cool
storage material charging inlet 24, the anaerobic adhesive 29 is
applied onto the inner circumferential surface of the cool storage
material charging inlet 24 (see FIGS. 4 and 5(a)). Subsequently,
through use of a left die 35 and a right die 36, the cool storage
material charging inlet 24 is pressed and collapsed from the
opposite sides with respect to the thickness direction of the
aluminum plates 19, to thereby form the outward protrusions 26
which are in close contact with each other. The left die 35 has a
rightward projecting convex portion 35a and a leftward recessing
concave portion 35b which are arranged in the vertical direction.
The right die 36 has a rightward recessing concave portion 36a and
a leftward projecting convex portion 36b which are arranged in the
vertical direction and which correspond to the convex portion 35a
and the concave portion 35b, respectively, of the left die 35.
Therefore, the convex portion 35a and concave portion 35b of the
left die 35 and the concave portion 36a and convex portion 36b of
the right die 36 bent the two outward protrusions 26 in the
thickness direction of the aluminum plates 19 such that each bent
portion has a V-shaped cross section. As a result, the two outward
protrusions 26 are bent at two locations spaced from each other in
the vertical direction such hat the adjacent bent portions 27
differ in bending direction (see FIG. 5(b)). After that, the two
outward protrusions 26 are left as they are for a predetermined
period of time, whereby the two outward protrusions 26 are bonded
together by the anaerobic adhesive 29. Thus, the seal portion 25 is
provided.
[0053] The above-described evaporator 1 with a cool storage
function constitutes a refrigeration cycle in combination with a
compressor driven by an engine of a vehicle, a condenser
(refrigerant cooler) for cooling the refrigerant discharged from
the compressor, and an expansion valve (pressure-reducing unit) for
reducing the pressure of the refrigerant having passed through the
condenser. The refrigeration cycle is installed, as a car air
conditioner, in a vehicle, such as an automobile, which temporarily
stops the engine, which serves as a drive source of the compressor,
when the vehicle is stopped. When the compressor is operating, low
pressure, two-phase refrigerant (a mixture of vapor refrigerant and
liquid refrigerant) having been compressed by the compressor and
having passed through the condenser and the expansion valve passes
through the refrigerant inlet 7, and enters the leeward upper
header section 5 of the evaporator 1. The refrigerant then passes
through all the heat exchange tubes 13, and flows out from the
refrigerant outlet 8 of the windward upper header section 6. When
the refrigerant flows through the heat exchange tubes 13, the
refrigerant performs heat exchange with air passing through the
air-passing clearances 15, and flows out in a vapor phase.
[0054] At that time, the cool storage material within the container
main body 21 of each cool storage material container 16 is cooled
by the cool carried by the refrigerant flowing through the heat
exchange tubes 13. Further, the cool carried by the cooled cool
storage material within the container main body 21 is transferred
through the inner fin 23 to the cool storage material within the
outward projecting portion 22 of the cool storage material
container 16, and the cool carried by air having passed through the
air-passing clearances 15 and cooled by the refrigerant is
transferred to the cool storage material within the outward
projecting portion 22. As a result, the cool is stored in the
entire cool storage material within the cool storage material
container 16.
[0055] When the compressor stops, the cool stored in the cool
storage material within the container main body portion 21 and
outward projecting portion 22 of each cool storage material
container 16 is transferred, through the inner fin 23, to the left
and right side walls of the container main body portion 21 and the
outward projecting portion 22. The cool transferred to the left and
right side walls of the container main body portion 21 passes
through the corresponding heat exchange tubes 13, and is
transferred, via the fin main body portions 31 of the outer fins 17
brazed to the heat exchange tubes 13, to air passing through the
air-passing clearances 15 adjacently located on the opposite sides
of the air-passing clearance 15 in which the cool storage material
container 16 is disposed. The cool transferred to the left and
right side walls of the outward projecting portion 22 is
transferred, via the outward projection portions 32 of the outer
fins 17 brazed to the left and right side surfaces of the outward
projecting portion 22, to air passing through the air-passing
clearances 15. Accordingly, even when the temperature of air having
passed through the evaporator 1 increases, the air is cooled, so
that a sharp drop in the cooling capacity can be prevented. FIGS.
6(a) and 6(b) and FIGS. 7(a) to 7(c) show modifications of the seal
portion provided on each cool storage material container 16 and
modifications of the method of providing the seal portion.
[0056] In the case of the seal portion 25 of the cool storage
material container 16 shown in FIGS. 6(a) and 6(b), the two outward
protrusions 26 are bonded together by an UV curable anaerobic
adhesive 40. The UV curable anaerobic adhesive 40 is hardened in a
state in which a portion of the UV curable anaerobic adhesive 40
has flowed outside from the joint interface between the two outward
protrusions 26 and has covered the outer end of the joint interface
(see FIG. 6(b)). The portion of the UV curable anaerobic adhesive
40 having flowed outside from the joint interface between the two
outward protrusions 26 is denoted by 40a. For example, LOCTITE
638UV (product of Henkel Corporation) is used as the UV curable
anaerobic adhesive 40. In this case, a stable gastightness and
bonding strength can be secured in a temperature range of
-40.degree. C. to 90.degree. C., which is the usual temperature
range of an environment in which the evaporator 1 is used.
[0057] The seal portion 25 of each cool storage material container
16, in which the UV curable anaerobic adhesive 40 is used, is
provided in the same manner as the seal portion 25 in which the
anaerobic adhesive 29 is used, except that the UV curable anaerobic
adhesive 40 is applied in place of the anaerobic adhesive 29.
[0058] However, the application amount of the UV curable anaerobic
adhesive 40 is determined such that, when the cool storage material
charging inlet 24 is pressed and collapsed, through use of the left
die 35 and the right die 36, from the opposite sides with respect
to the thickness direction of the aluminum plates 19, a portion of
the UV curable anaerobic adhesive 40 flows outside from the joint
interface between the two outward protrusions 26 and covers the
outer end of the joint interface.
[0059] The amount Z (mm.sup.3) of the UV curable anaerobic adhesive
40 applied onto the inner circumferential surface of the cool
storage material charging inlet 24 is preferably determined in
accordance with the following expression:
Z=L1.times.L2.times.L3
where L1 (mm) is the inner circumferential length of the cool
storage material charging inlet 24, L2 (mm) is the length (measured
in the vertical direction) of a portion of the inner
circumferential surface of the cool storage material charging inlet
24, on which portion the UV curable anaerobic adhesive 40 is
applied, and L3 (mm) is the spacing between the two outward
protrusions 26 after the cool storage material charging inlet 24 is
pressed and collapsed.
[0060] Finally, a UV light ray is applied to the adhesive and is
allowed to stand for a predetermined period of time, whereby the
two outward protrusions 26 are bonded together by the UV curable
anaerobic adhesive 40, and a squeezed-out, hardened portion 40a is
formed. Thus, the seal portion 25 is provided.
[0061] A seal portion 45 of the cool storage material container 16
shown in FIGS. 7(a) to 7(c) includes two outward protrusions 46
which are provided on the aluminum plates 19 such that they project
upward therefrom and which are brought into close contact with each
other. The two outward protrusions 46 are formed by pressing and
collapsing the cool storage material charging inlet 24 from the
outside with respect to the thickness direction of the cool storage
material container 16 such that the entire outward protrusions 46
become flat. The two outward protrusion 46 are bonded tighter by a
UV curable anaerobic adhesive 40. The UV curable anaerobic adhesive
40 is hardened in a state in which a portion of the UV curable
anaerobic adhesive 40 has flowed outside from the joint interface
between the two outward protrusions 46 and has covered the outer
end of the joint interface (see FIG. 7(c)). The portion of the UV
curable anaerobic adhesive 40 having flowed outside from the joint
interface is denoted by 40a.
[0062] The seal portion 45 of the cool storage material container
16 is provided as follows.
[0063] The method of providing the seal portion 45 is the same as
the case of the seal portion 25 in which the above-described
anaerobic adhesive 29 is used, up to the manufacture of the cool
storage material container 16 having the cool storage material
charging inlet 24. After the cool storage material is charged into
the cool storage material container 16 through the cool storage
material charging inlet 24, the UV curable anaerobic adhesive 40 is
applied onto the inner circumferential surface of the cool storage
material charging inlet 24 (see FIG. 7(a)). Subsequently, the cool
storage material charging inlet 24 is pressed and collapsed,
through use of first left and right dies 47, from the opposite
sides with respect to the thickness direction of the aluminum
plates 19. Each of mutually facing portions of the left and right
dies 47 has a vertical surface 47a, and a slant surface 47b which
extends upward from the upper end of the vertical surface 47a and
inclines outward in the left-right direction. The left and right
dies 47 deform upper portions (deformation portions) of the
semi-cylindrical portions 28 of the cool storage material charging
inlet 24. Specifically, lower parts of the deformation portions of
the semi-cylindrical portions 28 are collapsed and pressed against
each other by the vertical surfaces 47a, and upper parts of the
deformation portions are deformed to extend along the slant
surfaces 47b of the left and right dies 47. A portion of the UV
curable anaerobic adhesive 40 accumulates in a region between the
portions of the semi-cylindrical portions 28 extending along the
slant surfaces 47b of the left and right dies 47 (see FIG.
7(b)).
[0064] Subsequently, the entire semi-cylindrical portions 28 of the
cool storage material charging inlet 24 are pressed and collapsed
by second left and right dies 48. The left and right dies 48 have
vertical surfaces 48a formed over the entireties of the mutually
facing portions thereof. The vertical surfaces 48a of the left and
right dies 48 form the flat outward protrusions 46 and brings the
two outward protrusion 46 into close contact with each other. At
that time, the UV curable anaerobic adhesive 40 is caused to
partially flow out of the joint interface between the two outward
protrusions 46 and cover the outer end of the joint interface.
After that, a UV light ray is applied to the adhesive and is
allowed to stand for a predetermined period of time, whereby the
two outward protrusions 46 are bonded together by the UV curable
anaerobic adhesive 40. Thus, the seal portion 45 is provided.
[0065] The amount Z (mm.sup.3) of the UV curable anaerobic adhesive
40 applied onto the inner circumferential surface of the cool
storage material charging inlet 24 is preferably determined in
accordance with the following expression:
Z=L1.times.L2.times.L3
where L1 (mm) is the inner circumferential length of the cool
storage material charging inlet 24, L2 (mm) is the length (measured
in the vertical direction) of a portion of the inner
circumferential surface of the cool storage material charging inlet
24, on which portion the UV curable anaerobic adhesive 40 is
applied, and L3 (mm) is the spacing between the two outward
protrusions 46 after the cool storage material charging inlet 24 is
pressed and collapsed.
[0066] In the above-described embodiment, the thermal storage
material container according to the present invention is used as a
cool storage material container of an evaporator having a cool
storage function into which a cool storage material for storing
cool is charged. However, the present invention is not limited
thereto. In a heat exchanger having a plurality of heat exchange
tubes through which a medium for carrying heat flows, the thermal
storage material container according to the present invention may
be used as a heat storage material container into which a heat
storage material for storing heat is charged.
* * * * *